Welcome to our DW735 Planer Upgrade Support Hub
Thank you for your interest in the DW735 Planer Dust Collection Kit! Whether you're a proud owner or just exploring your options, this page is your go-to resource for setup, support, and everything you need to get the most out of your planer.
Your DW735 Planer Dust Collection Kit Options
We offer two primary options to suit your needs:
1. Digital Download
Start printing today! This option includes all the digital files you need to 3D print the Dust Boot and other components at home.
2. Fully Assembled Physical Unit
Ready to install right out of the box, our physical kits are available in four variations to fit your setup:
4-Inch or 6-Inch Size: Choose the size that works best for your dust collection system.
Optional Enhanced Mounting Screws: Upgrade for even better performance and stability.
Every physical kit includes:
Dust Boot in your selected size
Dust Port Safety Cover
Safety Switch Override for new and old machines
Installation Guide
Need help deciding? Visit our Contact Us for support.
Product Description
This download contains the latest updates for our aftermarket upgrade for the DeWALT DW735 planer, designed to modify the machine’s factory dust extraction method to an over-the-top dust collection system.
Now featuring Release 2025.05.12, this update includes the much-anticipated 6-inch Dust Boot option, along with enhancements to improve durability, compatibility, and ease of use.
What’s Included in This Download:
Dust Boot (v4.3) and (v4.5 Beta for 4”)
4-inch version: Printed in 3 parts and requires CA glue to assemble. New posts reinforce connections and reduce stress on glue joints.
6-inch version: Redesigned for larger dust collection setups.
Exhaust Cap: A friction-fit cover to protect your machine when not connected to a dust pipe.
Safety Switch Override
Updated to address compatibility with older and newer DW735 machines.
Printed in 2 parts and utilizes a bolt from the original cover.
Shop Vac Adapter
4-inch to 2.25-inch, 90-degree adapter for connecting the DW735 to a shop vacuum with a 2-1/4" hose.
Fan housing covering (Beta)
A new twist on cover for the fan housing to reduce air movement from the old shroud side
Assembly Instructions
Detailed PDF instructions for all parts included with the download.
File Types Provided:
STL files: For use with any 3D printing slicing software.
PrusaSlicer 3MF files: Pre-configured for easy customization.
Our Printer Setup:
Printers: Prusa MK4 and MK4S (our small farm has recently been upgraded).
Build Volume: 25×21×21 cm (9.84"×8.3"×8.3").
Material: Prusament, Jessie, or Polymaker PETG.
Print Settings:
Layer heights vary between 0.20mm and 0.30mm, pre-set in each model’s 3MF file.
Infill set to 15% Gyroid pattern for strength and efficiency.
Important Notes:
Dust Collector Required: For best results, use a dust collector with this upgrade. However, a Ridgid 6.5 HP Peak Shop Vacuum has been successfully used with the included adapter.
Warranty Disclaimer: This is an aftermarket upgrade that may void your planer’s warranty if you cut the cover. The part can be removed without issue, and no permanent modifications to the machine are required beyond the optional cover cut.
Safety Reminder: Overriding the cover safety switch increases the chance of injury. Always unplug the device when not in use or during adjustments.
Maintenance Tip: The fan does not need to be removed but should be cleaned along with the surrounding area for optimal performance.
User Responsibility: By using this product, the user assumes all risks and responsibilities for its safe use and operation. Proper installation, adherence to the provided instructions, and following standard safety practices are essential to ensure safety.
Additional Resources:
Assembly and Installation Video: https://youtu.be/HSStU_C2GiY
Model Fly-By: https://www.instagram.com/p/Cl98VS6ppRZ/
No Dust After Running 50 BDFT: https://www.instagram.com/p/ClxAgaZMWfS/
License Information:
This download is provided under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License:
https://creativecommons.org/licenses/by-nc-nd/4.0/
Free Bonus!
Don’t forget to grab our free Planer Thickness Gauge to make your woodworking projects even easier:
https://www.printables.com/model/320286-planer-thickness-gaugeCheck out other free downloads on Printables:
https://www.printables.com/@BuilderDadDan
Take your DeWALT DW735 planer to the next level with our Over-the-Top Dust Collection Kit—now available as a physical unit! This kit is designed for woodworkers who want a plug-and-play solution to improve dust collection, safety, and overall performance.
Enjoy free shipping on this kit, making it an even greater value!
What’s Included in the Kit:
Dust Boot (4" or 6")
Redesigned for superior dust extraction with mounting references for easy installation using existing dust shroud bolts—no extra hardware required.
Choose between the 4-inch version or the much-anticipated 6-inch Dust Boot.
Dust Port Safety Cover
A friction-fit cover to enhance safety by preventing accidental contact with the fan blade when the dust pipe is disconnected.
Safety Switch Override
Updated to accommodate differences in safety switch locations between older and newer DW735 models.
Easily installs using the existing cover bolt—no need to modify your planer.
Enhanced Mounting Screws (Optional)
Upgrade to ergonomic 5-point knob screws for easier manipulation and adjustment, replacing the standard 2-wing screws.
Shop Vac Adapter (Optional)
A 4-inch to 2.25-inch, 90-degree adapter for connecting the DW735 upgrade to shop vacuums with a 2-1/4" hose.
Installation Guide
Includes a detailed assembly guide and access to our YouTube tutorial for easy setup: Assembly and Installation Video.
Materials and Craftsmanship:
Each component is 3D printed using premium PETG filament for exceptional durability, strength, and heat resistance.
Important Notes:
Dust Collector Required: For best results, use a dust collector with this upgrade. However, a Ridgid 6.5 HP Peak Shop Vacuum has been successfully used with the included adapter.
Warranty Disclaimer: This is an aftermarket upgrade that may void your planer’s warranty if you cut the cover. The part can be removed without issue, and no permanent modifications to the machine are required beyond the optional cover cut.
Safety Reminder: Overriding the cover safety switch increases the chance of injury. Always unplug the device when not in use or during adjustments.
Maintenance Tip: The fan does not need to be removed but should be cleaned along with the surrounding area for optimal performance.
User Responsibility: By using this product, the user assumes all risks and responsibilities for its safe use and operation. Proper installation, adherence to the provided instructions, and following standard safety practices are essential to ensure safety.
Why Choose This Kit?
Upgrade your woodworking projects with a professionally crafted dust collection system that enhances performance and safety. Ideal for both professionals and DIY enthusiasts, this kit makes maintaining a cleaner, safer shop easier than ever.
📰 Latest News
The Long-Awaited Update is Here!
The 6-inch hose connection is now available for the Dust Boot Version 4.3! Inventory is currently printing, so you can get your hands on this upgraded solution soon.
🚀 Can’t wait? If you have a 3D printer, you don’t have to! The digital download includes all the files you need to start printing today.
Helpful Links:
Enhancing the DeWALT DW735 Planer: My Journey and Game-Changing Dust Collection Solution
Byrd Tool OEM Shelix Cutter Head: Upgrade your DW735 planer with the Shelix Cutter Head I use and swear by. It delivers cleaner cuts, requires less frequent blade changes, and is a game-changer for serious woodworking. Check It Out Here
DIY Universal Planer Cart: Build the mobile planer cart I use in my shop, inspired by a 2015 post from Chris Marshall on Woodworker's Journal. It’s a sturdy and versatile solution for your DW735 planer. Get the Instructions Here
Installation Video for DW735 Planer Kit
Dust Collection Tips (Coming Soon):
Join the Maker’s Lounge by Builder Dads: An exclusive Facebook group for Builder Dads customers and Patreon supporters. Connect with fellow woodworkers and 3D printing enthusiasts to share ideas, ask questions, and showcase your projects. Click Here to Join
Builder Dads Patreon Community: Get exclusive access to behind-the-scenes content, how-to guides, and more! Join Here